Erosion resistant and hydrophobic article

Patent metadata

Field	Value
Publication number	US-10814580-B2
Application number	US-201715810192-A
Country	US
Kind code	B2
Filing date	Nov 13, 2017
Priority date	Mar 9, 2012
Publication date	Oct 27, 2020
Grant date	Oct 27, 2020

Abstract

A gas turbine engine includes an airfoil having a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions.

First claim

What is claimed is:

1. A gas turbine engine comprising:
an airfoil having leading and trailing edges, the airfoil including a core having a first hardness and a surface at the leading edge on the core, the surface including a plurality of geometric features having a second, greater hardness and defining a surface porosity by area percent (SP) and a surface solidity by area percent (SS), the surface including a ratio of SS/SP that is 1.8 or greater, the plurality of geometric features and the ratio establishing the surface to be hydrophobic such that the surface would not be hydrophobic in absence of the plurality of geometric features or the ratio, and the second, greater hardness and the ratio establishing an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions such that the erosion rate of the surface would not be equal to or less than an erosion rate of the core in absence of the second, greater hardness or the ratio, wherein each of the plurality of geometric features extends along a respective central axis from a base at the core to a free end, the base defining a reference plane and the central axis being at a non-perpendicular angle to the reference plane, and the non-perpendicular angles are non-equivalent.

2. The gas turbine engine as recited in claim 1 , including a compressor section, a combustor in fluid communication with the compressor section and a turbine section in fluid communication with the combustor.

3. The gas turbine engine as recited in claim 1 , wherein a remaining surface of the airfoil excludes the plurality of geometric features.

4. The gas turbine engine as recited in claim 3 , wherein the remaining surface is smooth.

5. The gas turbine engine as recited in claim 1 , wherein each of the plurality of geometric features including a height (h) extending from the base to the free end and a maximum width (w) extending perpendicular to the height to define an aspect ratio w/h that is 0.004-4, wherein the plurality of geometric features include non-equivalent aspect ratios.

6. The gas turbine engine as recited in claim 1 , wherein the plurality of geometric features include a plurality of cylindrical elements.

7. The gas turbine engine as recited in claim 1 , wherein each of the plurality of geometric features includes an enlarged head at the free end.

8. The gas turbine engine as recited in claim 1 , wherein the non-perpendicular angle is less than 90° and greater than or equal to 20°.

9. The gas turbine engine as recited in claim 1 , wherein the base defines a reference plane and the free end has a surface that is sloped relative to the reference plane.

10. The gas turbine engine as recited in claim 1 , wherein the ratio is 15.7 or less.

11. The gas turbine engine as recited in claim 1 , wherein the plurality of geometric features are made of a metallic material.

12. The gas turbine engine as recited in claim 1 , wherein the plurality of geometric features are formed of ceramic material or intermetallic material.

13. A method of providing erosion protection and hydrophobicity in an article, the method comprising:
in an article that has a core and a surface on the core, establishing the surface to be hydrophobic by providing the surface with a plurality of geometric features defining a surface porosity by area percent (SP) and a surface solidity by area percent (SS) such that a ratio of SS/SP that is 1.8 or greater, wherein the surface would not be hydrophobic in absence of the plurality of geometric features or the ratio, wherein each of the plurality of geometric features extends along a respective central axis from a base at the core to a free end, the base defining a reference plane and the central axis being at a non-perpendicular angle to the reference plane, and the non-perpendicular angles are non-equivalent; and
establishing the surface to have an erosion rate that is equal to or less than an erosion rate of the core under identical erosion conditions by providing the ratio and providing the core with a first hardness and the plurality of geometric surface features with a second, greater hardness, wherein the erosion rate of the surface would not be equal to or less than an erosion rate of the core in absence of the second, greater hardness or the ratio.

14. The method as recited in claim 13 , including establishing the surface to be hydrophobic such that the ratio is 15.7 or less.

Assignees

• Raytheon Tech Corp

Inventors

• Schmidt Wayde R
• Beals James T
• Nardi Aaron T

Classifications

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• Y10T428/24479

  including variation in thickness · CPC title

• F05D2300/514

  Porosity · CPC title

• F01D5/286

  Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion (F01D5/288 takes precedence) · CPC title

• F05D2300/506

  Hardness · CPC title